Safewall storm room suite

ABSTRACT

Building a storm room suite within an existing home or existing building including methods and procedures to install are disclosed. The storm room suite is capable of being built within any existing room without regard to size, shape including room size, height, and roof spans. The uniqueness of said structure is that it is capable of being installed directly against existing walls and ceiling with minimal clearance between existing structure and new storm room. The storm room can include provisions for window shutters, specialty doors, mechanical, electrical, and ventilation.

BACKGROUND OF MY INVENTION

The Federal Emergency Management Agency (FEMA) is encouraging people toplace their families in a safe room, also referred to as storm room, orin shelters. Evacuation that takes place in densely populated areasthemselves can be dangerous due to traffic and weather.

It is desired to have a shelter that is incorporated into theconstruction of a home and able to withstand significant wind velocitiesand other catastrophic damages that occur from hurricanes and tornadoes.

The majority of new homes being built in the United States areconstructed of wood and no considerations or provisions are being takento construct any type of safe room or storm room within said newhousing. Furthermore there are millions of homes built within the last30 plus years that have no provisions to take shelter from any type ofstorms such as a tornado or a hurricane.

Limitations and disadvantages of building a concrete prefabricated,pre-cast, or concrete panelized shelter within an existing home orbuilding using methods available today make it impractical to constructany type of retrofit safe shelter. The following presentation of myinvention of designing and building a storm room, as referenced by thedrawings will become evident in comparison to traditional, and priorproposed approaches that have been available within the marketplace.

Finishes to interior walls and ceiling of my storm room such as drywalland decorative options can be added as required by others. Optional orsecondary functional uses for my completed storm room are; media hometheater, bedroom, bedroom and bathroom suite, craft room, office suite,panic room, and disaster recovery suite.

BRIEF SUMMARY OF MY INVENTION

The scope of my invention comprises of the preparation of any existingroom within a new or existing structure and the installation byfollowing written procedures to build a new cast-in-place reinforcedconcrete storm room against an existing wood, block or other wall,floor, and ceiling structures. The procedures include the preparationand modification of the existing structure by removing any requireddoors, windows, trim, fixtures, and miscellaneous dividers such asclosets, partitions, etc. The connection and anchoring of my inventionto minimize uplift and enhance anchorage to existing ground and existingconcrete floor is done by first; drilling and anchoring reinforcingsteel into the existing concrete floor, second; by core boring openingsat specific locations through existing concrete floor and then excavateto a specific level below the concrete floor for the purpose ofinterrogating a poured-in-place concrete column with reinforcing steelinto the new concrete reinforced walls and ceiling of storm room.Reinforced concrete columns along with anchoring reinforcing steel intothe existing concrete floor will then act as an anchor to keep stormroom suite from uplift and destruction when storm events are happening.

Lightweight angles will be installed in all 90-degree interior cornersto add to integrity and support of high impact resistant wallboard,which becomes part of the cast-in-place concrete wall system. Highimpact resistant wallboard properties are mold and fungus free, waterresistant, fire resistant, insect resistant, and has high structuralimpact resistance qualities.

All existing walls next to new storm room system will be covered withhigh impact resistant wallboard. Wallboard panels will havepre-installed metal tie rod plates at specific locations in accordanceto prescribed wall pressure of concrete that will be poured to completethe cast-in-place concrete wall system. High impact resistant wallboardwill be non-structurally secured to existing walls by screws or otheranchors to complete the fasting to the wood or block wall system.

Window and door openings will then be framed to accept finish storm roomsafety door and optional exterior mounted window shutter. Electricalboxes and any special fixture mounts will then be mounted and secured atproper locations. All joints including walls, ties, electrical, windowand door openings will be sealed with a sealant to prevent any liquidfrom penetrating into existing walls from fluid concrete prior toconcrete hardening.

Wall and ceiling reinforcing steel is installed and window supportshutter frame is mounted and secured prior to installing inside formingpanel system.

Interior removable Z-Panel, wood, or aluminum forms will be connected tometal tie rod plates. All hardware and bracing equipment will beinstalled and secured on or against forms in accordance with bestengineering system practices. Ceiling forming to consist of either highimpact wallboard, Z-panels, wood, or aluminum type forms, and shoring asper best engineering practices.

Concrete specialty pumping valves will be installed either in the windowframes, doorframes, or the wall forms themselves prior to placing theconcrete within the cast-in-place wall system. The ceiling shallincorporate my combination air and concrete pumping assembly system. Theinfill of structural concrete shall be pumped and controlled by anindustry standard concrete pump.

Temporary installed forms on the interior of the cast-in-place stormroom system walls and ceiling upon sufficient setting and curing of theconcrete are removed and all fixtures including window shutter and doorinstallation assembly then will be installed. High impact wallboard ifused, as interior form may remain in place and be used as a finishedwall-covering product. Finishes to interior walls and ceiling of mystorm room such as drywall and decorative options can be added asrequired by others. Secondary functional uses for my completed stormroom suite are; closets, storage, media theater rooms, bedrooms, bedroomand bathroom suites, office suites, craft room suites, panic rooms, anddisaster recovery suites.

The advantages and novel features of my invention, as well as details ofillustrated embodiments thereof, will be more fully understood from thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 EXISTING ROOM DEMOLITION PROCEDURES.

FIG. 2 CONCRETE FOUNDATION PIER AND REINFORCING STEEL ANCHORINGPROCEDURES.

FIG. 3 HIGH IMPACT RESISTANT WALLBOARD INSTALLATION DRAWING.

FIG. 4 HIGH IMPACT RESISTANT WALLBOARD DETAILS AND DRAWINGS.

FIG. 5 HIGH IMPACT RESISTANT WALLBOARD DETAILS AND DRAWINGS. PAGE

FIG. 6 REINFORCING STEEL WALL DETAILS.

FIG. 6 a REINFORCING STEEL WALL DETAILS.

FIG. 7 REINFORCING STEEL CEILING LAYOUT WITH AIR AND CONCRETE PUMPINGASSEMBLY AND ELECTRICAL BOX.

FIG. 8 INTERIOR OF STORM ROOM FORM AND SHORING DESIGN LAYOUT INCLUDINGVIEW OF AIR AND CONCRETE PUMPING ASSEMBLY.

FIG. 9 STORM ROOM WALL DETAIL CROSS SECTION USING Z-PANELS, WOOD, STEEL,OR ALUMINUM FORMS.

FIG. 10 WALLBOARD CONNECTION BRACKETS DETAILS.

FIG. 10 a WALLBOARD CONNECTION BRACKETS DETAILS.

FIG. 11 THROUGH WALL CONNECTION BRACKETS DETAILS.

FIG. 12 AIR AND CONCRETE PUMPING ASSEMBLY DETAIL DRAWINGS.

FIG. 13 EXTERIOR MOUNT (INTERIOR OPERATED) WINDOW SHUTTER.

DETAILED DESCRIPTION OF MY INVENTION

With reference now to the drawings in which like elements are denotedwith the same numeral throughout the several views. The uniqueness of myinvention is that the structural cast-in-place concrete wall system canbe built directly against any existing wall and ceiling within a home orbuilding. The high impact wallboard, cast-in-place concrete includingall attachments to wall assemblies comprises the completepoured-in-place explained wall system invention. Additional systemelements, which are described within the FIG. Drawings 1 through 13 areincluded.

Prior to the installation of my invention, demolition procedures may berequired. FIG. 1 depicts a sample room layout and the following isrequired prior to building storm room. Remove 10 closet doors and allcloset 20 stud walls. Remove 30 existing entrance door and expand 40width of opening to match new storm room door and frame. Remove 50 allbase and 51 ceiling molding materials. Remove 60 window trim asrequired. Remove 70 wall plug and switch 80 plate covers and lightfixtures. Tape and secure electrical ends. Complete all roommodifications and/or additions as required.

Core bore holes in existing concrete 90 as shown in FIG. 2 next toexisting walls and directly beneath new storm room wall system. Continueto excavate FIG. 3 into ground 100 until firm ground is established orto an acceptable depth below the top of existing concrete floor. Installreinforcing steel 110 into new pier and extend up into the newcast-in-place wall system. Piers may be monolithic poured at same timeupper structural concrete walls are poured creating a complete attachedpier and wall structural system.

Drill holes 120 in existing concrete floor as shown in FIG. 2 to a depthnot to exceed 75% of depth of floor. Size of drilled holes to correspondand match reinforcing steel that is to be installed. Anchor eitherreinforcing steel dowel with sufficient bar lap or sized reinforcingsteel to exact height as required and include a 90 degree hook on top toextend into the roof structure of my invention.

Install corner angle steel 130 FIG. 2 by securing into existing wallswith screw or anchors. Attach wall tie hardware to wallboard as shown inFIGS. 4, 5, 8, 9, 10, 10 a, and 11. There are two types of anchorpressure plates shown that can be used to connect the exterior wallboardof the cast-in-place wall system to the tie rod that connects to theinterior forms of wall system. The first type of anchor pressure plate400 is shown on FIG. 5, and FIG. 10 that is rectangular in sharp withfemale fittings 411 to accept threaded tie rod end 441. The second typeof anchor pressure plate 410 round and flat and is shown on FIG. 4, FIG.9, FIG. 10 a, and FIG. 11 with female fittings 411 to accept threadedtie rod end 441. There are three types of tie rods shown that can beused to connect the anchor pressure plates on the exterior wallboard tothe interior form of the concrete cast-in-place wall system and all tierods are interchangeable with each other depending on type on interiorform type used. The first type of tie rod 420 FIG. 11 has a threaded 421end that can be used with any wood form. The end portion of 420 that thewood form is attached to is considered standard within the industry andmany accessories are available for wood form to tie end. The second typeof tie rod 430 FIG. 11 has 431 a threaded end and a threaded end adapter432 that is attached to Z-panel form type. The Z-panel form system ismade of high-density grade fiberglass with attachments to secure form totie end. The third type of tie rod 440 FIG. 11 has 441 a threaded endand a attached flat tie with a pin 442 hole to anchor metal or aluminumforms. The end portion of 440 that the metal or aluminum form isattached to is considered standard within the industry and manyaccessories are available secure metal or aluminum form to tie end.

Install impact resistant wallboard 140 FIG. 3 to existing walls. Highimpact resistant wallboard panels to be secured to FIG. 9 existing wallstuds 141 and drywall 142 if walls are wood or structural secured intoblock walls if required. Seal all joints to avoid leaching of concretewhile in the fluid state.

Install window 150 FIG. 6 and door FIG. 6 a edge form 160 framing FIG. 6a to a dept as required for wall thickness. Both door and window formsto include concrete pump hose inlet connections as required to completeconcrete pour operation. The next step is to install my special FIG. 13mount interior operated secured window shutter frame directly overwindow edge form and secure as required. The summary of my securedshutter is the angle side mount frames 331 anchored with anchor studs332. The top angle is a lightweight anchor nailing fin 333 attached to ametal encasement 330 which contains the shutter 334 material. Theshutter becomes mounted on the exterior side of my invention and can beoperated from within the interior of my invention. My secured windowshutter becomes encased into FIG. 9 the cast-in-place concrete wallsystem 335 for securement.

Install necessary electrical extensions, new electrical conduit, andmechanical sleeves and secure against leakage of fluid concrete fill.Install wall reinforcing steel FIGS. 6 and 6 a and ceiling FIG. 7reinforcing steel 110 as detailed. Mount in ceiling FIG. 7, FIG. 8 andFIG. 12 air and concrete pumping assembly 170 and anchor 180 as FIG. 12required. The top part of the assembly FIG. 12 is made of “U” shapedpiping attached to a threaded sleeve 200. The top of the sleeve has aplate 210 attached for anchoring to reinforcing steel for support. Pipe220 and then is attached to a fitting 230 that will accept a concretepumping hose.

Install interior wall Z-Panel, wood, or aluminum forms complete with allbracing and accessories as shown on FIG. 8 and FIG. 9. Install Z-panels,wood, or aluminum Structural ceiling panels and FIG. 8 shoring 250, 260,270 to complete forming system. Pour structural designed concrete 280through concrete pumping assemblies FIG. 12 into storm room wall andceiling and vibrate as required. Upon proper curing, remove interiorforms and ceiling re-shoring from new cast-in-place wall and ceilingsystem. Install fixtures and wall finish coverings over invention as perdesign and specifications. Finishes to interior walls and ceiling of mynew storm room such as drywall and decorative options can be added asrequired by others. Secondary functional uses for my completed stormroom suite are; closets, storage, media theater suites, bedroom suites,office suites, bathroom suites, panic room suites, and disaster recoverysuites.

While my invention has been described with reference to certainembodiments, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted withoutdeparting from the scope of the invention. In addition, manymodifications may be made to adapt a particular situation or material tothe teachings of my invention without departing from its scope.Therefore, it is intended that my invention not be limited to theparticular embodiment disclosed, but that my invention will include allembodiments falling within the scope of the appended claims and theirlegal equivalents.

1. A method comprising of building a storm room within a home orbuilding including a poured in place concrete system with minimal walland ceiling clearance between existing structure and storm room suiteincluding procedures to anchor storm room invention to the ground, andthe capability of building storm room within any room without regard tosize, shape, including room size, height and ceiling span's.
 2. A methodcomprising of building a storm room of claim 1, wherein minimal wall andceiling clearance means that my storm room can be built directly againstany existing walls of the home or building without any substantialspacing or gaps.
 3. A method comprising of building a storm room ofclaim 1, wherein anchoring of the storm room to ground will enhance theintegrity of my invention in regards to up-lift in the event of anycatastrophic damages that occur from hurricanes and tornadoes.
 4. Amethod comprising of building a storm room of claim 3, wherein theanchoring consist of cutting holes into the existing concrete floor slaband excavating existing fill and replacing excavated space withconcrete.
 5. A method comprising of building a storm room of claim 4,wherein the concrete is reinforced with reinforcing steel.
 6. A methodcomprising of building a storm room of claim 3, wherein the anchoringalso consist of drilling holes into the existing concrete floor andinstalling anchors to connect the existing foundation to the storm roomsuite.
 7. A method comprising of building a storm room of claim 1,wherein the storm room is not restricted to size, shape, and room heightbecause it is conventionally built in place and not dependant on beingset into place prior to building the home or building.
 8. A methodcomprising of building a storm room of claim 1, wherein the storm roomis not restricted to size, shape, and room height because it issubstantially built in place and not dependant on being set into placethrough existing doors and other openings within home or building.
 9. Amethod comprising of building a storm room suite within a home orbuilding including a poured in place concrete system with minimal walland ceiling clearance between existing structure and storm room suiteincluding procedures to anchor storm room invention to the ground, andthe capability of building storm room within any room without regard tosize, shape, including room size, height and ceiling span's.
 10. Amethod comprising of building a storm room suite of claim 9, whereinmeans that the invention may contain more than one room and be accessedto each room by a common walk through opening and to include one openingas entrance to or exit from the invention.
 11. A method comprising ofbuilding a storm room suite of claim 9, wherein the storm room is madeof wallboard, tie rods, reinforcing steel, and concrete.
 12. A methodcomprising of building a storm room suite of claim 11, wherein thewallboard is made of a durable grade material.
 13. A method comprisingof building a storm room suite of claim 12, wherein the durable gradematerial is magnesium oxide board.
 14. A method comprising of building astorm room suite of claim 12, wherein the durable grade material hasopenings to receive the tie rods for holding the fluid concretetogether.
 15. A method comprising of building a storm room suite ofclaim 14, wherein the tie rods has an attached round or square flat diskto one end of the tie rod.
 16. A method comprising of building a stormroom suite of claim 15, wherein the attached round or square flat diskis anchored to the durable grade material.
 17. A method comprising ofbuilding a storm room of claim 15, wherein the tie rods has an attachedform to the other end of the tie rod.
 18. A method comprising ofbuilding a storm room of claim 17, wherein the attached form is made ofZ-panel, wood, or aluminum.
 19. A method comprising of building a stormroom of claim 11, wherein the wallboard is installed against existingwalls.
 20. A method comprising of building a storm room suite of claim19, wherein the wallboard is attached with anchors.
 21. A methodcomprising of building a storm room suite of claim 20, wherein theanchors are nails or screws.
 22. A method comprising of building a stormroom within a home or building including a poured in place concretesystem, air assembly system, with minimal wall and ceiling clearancebetween existing structure and storm room including procedures to anchorstorm room invention to the ground, and the capability of building stormroom within any room without regard to size, shape, including room size,height and ceiling span's.
 23. A method comprising of building a stormroom of claim 22, wherein the air assembly system is used to circulateair in and out of the invention.
 24. A method comprising of building astorm room of claim 22, wherein the air assembly system is used to pumpfluid concrete into the invention.
 25. A method comprising of building astorm room of claim 22, wherein the air assembly system is made ofdurable material.
 26. A method comprising of building a storm room ofclaim 25, wherein the durable material is made of either steel or PVC.27. A method comprising of building a storm room within a home orbuilding including a poured in place concrete system with minimal walland ceiling clearance between structure and storm room suite includingprocedures to install anchoring system to connect storm room inventionto the ground, window storm shutter, and the capability of beinginstalled within any room without regard to size, or shape.
 28. A methodcomprising of building a storm room of claim 27, wherein the windowstorm shutter is mounted on the exterior of the invention.
 29. A methodcomprising of building a storm room of claim 27, wherein the windowstorm shutter is operated from within the invention.
 30. A methodcomprising of building a storm room of claim 27, wherein the windowstorm shutter is made of durable materials.
 31. A method comprising ofbuilding a storm room of claim 30, wherein the durable materials consistof a frame, nailing fin and window material encasement, and windowcover.
 32. A method comprising of building a storm room of claim 31,wherein the window frame is made of durable materials with durableanchors installed.